THE DESIGN We are concerned with the design of the hoisting arrangement of 2 tonne capacity of EOT crane ,which

will lift the load up to a distance of 8 meters. 1.DESIGN OF HOOK

HOOK

hook-cross-section

LINK

SHEAVE

Selection of section : The section is trapezoidal Selection of material : Mild steel Load to lift : 2 tonne Considering 50 % over loading. So the design load = 2 tonne+50% of 2 tonne = 3tonne Taking the help of (IS 3815-1969) for selection of material for 8 dimensions of crane hook.In IS 3815-1969 the nearest selection for 3.3 tonne is 3.2 tonne. For load 3.2, proof load (P) is 6.4 tonne. So C = 26.73P = 26.73 x 6.4 = 67.62 68 mm A = 2.75 C = 2.75 x 68 187 mm B = 1.31 C = 1.31 x 68 89mm D = 1.44 x C = 1.44 x 68 98mm E = 1.25C = 1.25 x 68 85mm F = C = 68mm G = 35mm G1 = M33, Pitch = 6mm (Coarse series) H = 0.93 x C = 0.93 x 68 63mm J = 0.75 x C = 0.75 x 68 51mm K = 0.92 x C = 63mm L = 0.7 x C = 0.7 x 68 48mm M = 0.6 x C = 0.6 x 68 41mm N = 1.2 x C = 82mm P = 0.5 x C = 34mm 34mm R = 0.5 x C = 0.5 x 68 U = 0.33 x C = 0.3 x 6820 mm Checking for strength Area of the section = x 63 x (41+8) = 1543.5 mm2 Centroid from a = (.05 x 8 x 65) 63/3+(.5 x 41 x 63) x (2 x 63)/3 x 68 x (41+8) = 38.571mm = 38.6 mm= h2 So centroid from b = 63-38.6=24.4mm =h1 0 = 34 +24.4 = 58.4mm r0 = A/(dA/u) dA/u = [b2+r2/h (b1-b2)] ln r2/r1 (b1-b2) =28.65mm r0 = A/(dA/u) = 1543.5 = 53.9 mm. 53.87 28.65 0-r0 = 58.4 53.9 = 4.5mm e=

Moment 0M = -P x = -3 x 58.4 = 175.2 (tonne x mm) Stress due to bending is given by b = M X 4 Ae r0-y For point a Y = -(e+h2) = -(4.5+38.6) = 43.1 mm For point b Y = r0-r1 = 53.9 3.4 = 19.9 mm Stress due to direct loading = P/A = 3/1543.5 = 1.9436 x 10-3 Tonne/mm3 Stress due to curvature of a ba = (-175.2) x -43.1 1543.5 x 4.5 {53.99 (-43.1)} = 0.0112 So total tress at a = 0.0112 + 1.9436 x 10-3 = 9.2642 x 10-3 Tonne/mm2 -90.85 Mp = 9.2642 kg/mm2 Stress due to curvature at b bb = -(-175.2) x . 19.99 . 1543.5x 4.5 (53.9 19.9) = 0.014763 So total stress at b bb + 1.9436 x10-3 = =0.014763 + 1.9436 x 10-3 =0.0167 tonne/mm2 163.84 MPa = 16.7 Kg/mm2 Let the material be class 4 carbon steel ( 55C 8) Ultimate tensil strength I 710MPa Design strength = Ultimate tensil strength Factor of safety = 710/4 = 177.5 MPa 163.84 > 177.5 So design is safe

Determination of length of threaded portion Pitch = 6mm Nominal dia of thread = 33 mm (G1) = d Considering the screw and thread are of single safest & square mean diameter of screw = dm = d- (p/2) = 33 (6/2) = 30 x 30) dm = 6/( = 1/ tan = tan-1 tan x 30)} = 3.640 { 6/( Let the co-efficient of fraction be 0.15 = 0.15 = tan So = 8.530 Torque required to resist the load )+ = W x dm* tan ( T 2 Where w is the weight of load is 3 tonne and the load of the hook itself. The maximum weight of the hook is 50kg (from the use of the soft ware Pro-Engineer) So T = 3050x 30 x tan (3.61+ 8.53) 2 =9866.42 Kgmm Stress induced in the screw Direct tensible stress (allowable or design) d02=4w/ d0 = core diameter of the screw. dc = d-p = 33-6 = 27 mm 1 = 4x 3050 272 = 52.24MR 5.326 kg/mm2 Torssional shear stress = 16T = 169866.42 de3 x 273 = 2.5529 Kg/mm2 = 25MP Maximum shear stress in the screw 2) + 4 ( 2 max = = (52.242 + 4 x 252) max = 36.15Mpa= Height of the nut a)Considering bearing action between the thread in engagement. Let n is no of thread in engagement with screw. Considering bearing action between nut & screw. Let the permissible bearing pressure =pi= 6 MR. We know

Pi = 4W (d2-dc2) x n So 6 = 43050 x 9.8 (332-272) x n N = 4 x 3050 x 9.8 (332-272) x 6 1.27 x 9.8 12.5 So the height of the nut is = 2 x 12.5 = 25mm. b) Considering shear failure of thread across root Shear stress induced =.W. dc(0.5xP) xn = . 3050 x 9.8 . x 27 x (0.5 x 6) x n = 117.46 n = 0.5 x 177.5 = 117.46 nn = 117.46 177.5 x0.5 = 1.32 = 2 So height is n x p = 2 x 6 =12mm Tacking the highest value 25mm Design of pin which will carry the dead load & the load of hook. We have to determine the dimension of t. n = M x Y I = M x (24) I2 Where I is moment of inertial about bh3 t x 243 x 2 12 12 Maximum bending moment for = M = x W x L Let L = 70 mm So M = x 3050 x 70 = 2 x 26687.5 Kgmm. = 2 x 261.715 x 103 N-mm = 2x 261.715 x 103 x 24 1 t x 243 2 177.5 = 1363 x 2 t t = 1363 x 2 = 15.2 MM 7.8 x 2 177.5 16 mm

Taking 20 m for additional safety Diameter of the projected portion The projected position is undergo only shearing failure. = 0.5 x design tensive stress. Design shear stress Force action on each side i.e. projected portion is 14.95 x 1033050/2 =1525 kg 15 KN So the minimum value of the height of the projected portion is 15mm, taking n= 40mm for screwing arrangement. = 15 x 103 /4 x dk2 = 177.5 x 0.5 = 15 x 103 /4) dk2 ( = dk2 = 15 x 103 x 4 177.5 x 0.5 x = dk2 = 15 x 103 x 4 177.5 x 0.5 x = 215.19 = 14.66 15mm Taking 20 mm for additional safety purpose. So that it can be turned to thread in size m20. Height of the projected portion P * x * dk = w/2 Where p = bearing pressure or crushing stress. Let p = 210 MPx Allow crushing stress =210/4 = 210/4 x x x 20 = 3050 x 9.8 2 x = 3050 x 9.8 x 5 2 x 20 x 210 = 3.56 mm x 4 = 14.024 =15 mm So the minimum value of the height of the projected portion is 15 mm, taking x = 40 mm for screwing arrangement. Design of link and the cover plate

coverplate

Thickness of link and cover plate should not be minimum. Let the material be (55C8). a)Hole fopr placing the pin which will carry the hook will be dk i.e. 20 mm. zchecking for the failure of link & cover plate combindely(as they are of same material and undergone same condition of failure). Mode of failure Tearing of cover plate & link at the edge. Crushing of cover plate and link. Breaking at the lowest cross section. i).Considering tearing of cover plate & link at the edge Experiments from the riveted joints have shown that if the distance between the centre of rivet and the edge is 1.5 times the diameter of the rivet.The element will not undergo the failure of tearing at the edge. The same condition is also applicable in our case. But for more safety reasons taking the distance between the centre of the projected element and the edge of the cover plate & linkis 2 times the dia of the projected element. So Z = 2 x dk = 2 x 20 = 40 mm Considering tensile failure at the lower cross section So d = w/2 A 177.5 = 3050 x 9.8/2 2 x x x 30 x = 3050 x 9.8/2 2 x 30 x 177.5

= 28/2 mm 1.4 mm Considering crushing failure Force = crushing(d) x projected area 3050 x 9.8 = crushing(d) x (20 x x) FOS = 3050 x 9.8 x 4 = 14.24 mm 15 mm 2 x 210 x 20 So taking maximum of x i.e 15 mm, So x = 15 mm

cover-plate-auto-cad

AutoCAD drawing Of Cover plate

auto_link Auto CAD

AutoCAD Drawing Of Link Design of shaft carrying the pulley

shaft to carry pully

Pulley

The weight of each cover plate is 2.5 kg. Weights of each link weigh 2 kg. So weight of 2 covers plate & 2 link Is 2 x 2.5 + 2 x 2 = 9 kg. So the total weight which the shafts carry is 3050 + 9 = 3059 3060 Each Side subjected to a load of 3060/2 = 1530 kg. The shaft is only subjected to Crushing failure (at the cover plate and link). Shear failure. Crushing failure (at the pulley)

Considering shear failure = f/a = allowable shear stress = 0.5 x 177.5 = 0 .5 x 177.5 = 22.2 MR FOS 4 Stress induced = 1530 x 9.8 = 150042 /4 x 302 /4 x 302 = 21.22 MPa As induced stress is less than that allowable stress, the design is safe Considering crushing failure at the cover plate Crushing stress = Force/Protected area Allowable stress = 240/4 = 60MPa Induced Crushing stress = Force Projected area = 3060 x 9.8 70 x 40 As allowable induced stress 60.86 KN. The selection is feasible. Design of Sheave

sheave

a = 40mm b = 30mm c = 7mm d = 18mm e = 1mm l = 10mm r = 12mm

r4 = 8mm h = 25mm r1 = 4mm r2 = 3mm r3 = 12mm Material is caste iron Let dia of the sheave = 20 x d = 20 x 14 = 240mm The reference is made from Rudenko,N.Materials Handling Equipment ,Mir Publishers, Moscow(1969). P .86,Table 16. Drum design Drum grove size Referring to Redenko,N Materials Handing Equipment,Mir publishers,Moscow (1969),P.No.90 table 17. Considering standard groove of drum, for, diameter of wire 15 mm as it is nearest to 14mm. Drum diameter = sheeve diameter = 240 mm. r 1 = 0.53 x d (d 15) = 9mm s1 = 1.15d = 17mm C1 = 0.25 d = 5mm No. of turn on each side of drum Z = (hi/d) + 2 = Where H = Lifting Height. I = Ratio of the pulley system. D = Drum diameter 45 x 14 = 630 So Z = ( 8.00 x 2) + 2 x63 Z = 10 Full lenth of drum for one rope. L = (2HI + 7)Si (I = 2 assumed) D =(2 x 800 x 2 + 7)1.5 =34.75 35 cm The drum is made up of IS grade = SG 80/2 With stress = 480Mpa W = 0.02 x 630 = 10 = 22.6 23 mm Outside dia of the drum Do = D + 6d = 630 + 6 x 14 = 714mm

Inside dia of the drum = Di = D 2W = 630 2 x 25 = 584 mm Checking of strength Bending Stress in drum bend = 8WLD (D4 Di4) = 8 x 6200 x 9.8 x 35 x 630 x (6304 5844) = 0.0828MP Maximun Torque Tmax = W (D + d) 2 = 6200 x 9.8 (630 + 14) 2 = 19.564 x 106 Maximum Shear Stress = 16 Tmax D (D4 Di4) = 16 x 19.56 x 106 x 630 x (6304 5844) 1.523 MPx Direct Compressive Stress = W = c wSi = 6200 x 9.8 23 x 17 = 155.4MPx Maximum Stress in the Drum max2 = bend2 + c2 + 4 = (0.08282 +155.42 = 4 x 1.5232)1/2 < 480 MPx, S the Design is safe. Fastening Of Rope With The Drum For 14 mm dia Locating Dimension Pitch of screw = 53 mm T = 43 mm Screw size Lo = 18 mm L = 50 mm Plate C = 7 mm No. of fastenings = 1

Selection of Motor W = 3100 kg x 9.8 m/s2 V = 0.2m/sec So power required = 3100 x 9.8 x 0.2 = 6080.123Nm/sec = 6.08 Kwatt Taking 11 Kwatt 3 phase induction motor (flange type) of 11 KW (nearest to 6.08KW) Frame No. 132 M Flange designation F265B The speed is 1000 RPM By using gear box the speed can be reduced to 300 RPM GearBox Calculation Gearbox ratio = (Input RPM x x rope drum dia) (speed x no. of falls /2) = ( 980 x x .714) = 183.54 (3.00 x 4 ) Brake calculation Required Brake Torque = 1.5 x 716.2 x mech H.P. Motor RPM = 1.5 x 716.2 x 50.12 300 = 53.84 Nm Design of wormset Power = P = 6.08 Kwatt RPM of Worm = Nw = V x 60 d = 0.2 x 60 x 0.63 RPM of Worm Gear NG = 300 RPM So R = NG Nw = 300 6 Let = 14.5o Let the centre distance = C = 300 mm =0.3m Pitch circle diameter of the worm Dw = C.8750 = 3Pc 3.48 Dw = 3.8750 = 0.10020m 3.48 100mm Dw = 3Pc = 3Pa = 3 x x ma

So ma = Dw/3 = 100.2/3 = 10.63 mm 11mm Pitch circle dia of the gear Dg = 2C Dw = 2x 300 100 = 500 mm Velocity ratio = Ng/Nw = 50 Ng/Nw = Dg /(ma x Nw) 50 = Dg/(11 x Nw) Dg = 50 x 11 x Nw

Taking Ng = 1 , because Dw is closer to the calculated. So, Dg = 550 Dw = 2C Dg = 2 x 300 -500 = 50mm Face width of the gear b = 0.73 x Dw = 0.73 x 50 = 36.5 = 40 mm Static strength of Bronze d = 90MPa In worm drive irrespective of materials of worm and worm ger,the gear is weak. So design should be based on gear. Tangential load on the gear : Ft = mn y b = (d x Cv) mn y b Velocity factor Cv = 6 . 6 + Vg Vg = x Dg x Ng 60 = 8.69 Cv = 6 = 0.41 6 + 8.69 Form factor Y = 0.124 0.684 Ng = 0.11132 Tan = m x Nw Dw

= 11 x 1 50 = tan-1 (.22) = 12.4o Nominal Module = m (ma) x cos = 11 x cos 12.4 = 10.743 mm Ft = 90 x .41 x x 1o.743 x .11132 x 40 = 5545.47 N = 5.55 KN Power Capacity = P1 = Ft x Vg = 5.55 x 103 x 8.69 = 48.19 K watt Which is greater than capacity so the design is safe. Powe capacity of drive from wear point of view P2 = Dg x b x W x Vg = 550 x 40 x W x 8.64 W = .550 = Material combination factor. For worm and worm gear made up of hardened steel and phosphor bronze So, P2 = (550 / 1000) x 40 x .55 x 8.64 = 104.4 Kwatt Power capacityof the drive, from the heat dissipation point of view is given by : P3 = 3650 x C17 R+5 = 3650 x 300 17 50 + 5 = 361.99K watt So The safe power capacity is minimum i.e P1 = 48.19 Kw CONCLUSION : The design of the hoist of EOT crane is done Numerically .We can implement the design practically in industries for various lifting jobs. (For More Information Regarding This Topic Please Give Your Email id )